EP2132043B2 - Method for producing a flat, printed component - Google Patents
Method for producing a flat, printed component Download PDFInfo
- Publication number
- EP2132043B2 EP2132043B2 EP08716179.0A EP08716179A EP2132043B2 EP 2132043 B2 EP2132043 B2 EP 2132043B2 EP 08716179 A EP08716179 A EP 08716179A EP 2132043 B2 EP2132043 B2 EP 2132043B2
- Authority
- EP
- European Patent Office
- Prior art keywords
- layer
- paper layer
- resin
- ink
- paper
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 14
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- 239000011347 resin Substances 0.000 claims abstract description 94
- 239000010410 layer Substances 0.000 claims description 283
- 238000000034 method Methods 0.000 claims description 61
- 238000007639 printing Methods 0.000 claims description 37
- 239000007788 liquid Substances 0.000 claims description 29
- 239000011241 protective layer Substances 0.000 claims description 26
- 238000003825 pressing Methods 0.000 claims description 25
- 230000004888 barrier function Effects 0.000 claims description 24
- 238000001035 drying Methods 0.000 claims description 15
- 238000010438 heat treatment Methods 0.000 claims description 15
- 230000008569 process Effects 0.000 claims description 10
- 239000002245 particle Substances 0.000 claims description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 8
- 239000000123 paper Substances 0.000 description 190
- 239000000976 ink Substances 0.000 description 60
- 239000000049 pigment Substances 0.000 description 18
- 239000011248 coating agent Substances 0.000 description 7
- 238000000576 coating method Methods 0.000 description 7
- 239000007787 solid Substances 0.000 description 7
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 6
- 239000011230 binding agent Substances 0.000 description 6
- 238000007641 inkjet printing Methods 0.000 description 6
- 239000000463 material Substances 0.000 description 5
- 230000007704 transition Effects 0.000 description 5
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 4
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 4
- 230000006835 compression Effects 0.000 description 4
- 238000007906 compression Methods 0.000 description 4
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- 239000003973 paint Substances 0.000 description 4
- 239000002250 absorbent Substances 0.000 description 3
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- 230000008901 benefit Effects 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 239000000975 dye Substances 0.000 description 3
- 238000007646 gravure printing Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 229920003002 synthetic resin Polymers 0.000 description 3
- 239000000057 synthetic resin Substances 0.000 description 3
- 239000004408 titanium dioxide Substances 0.000 description 3
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 2
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 229920000877 Melamine resin Polymers 0.000 description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 description 2
- 206010040007 Sense of oppression Diseases 0.000 description 2
- 229920002472 Starch Polymers 0.000 description 2
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 2
- 230000002745 absorbent Effects 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 2
- 235000012211 aluminium silicate Nutrition 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 229910000019 calcium carbonate Inorganic materials 0.000 description 2
- 239000006229 carbon black Substances 0.000 description 2
- 239000001768 carboxy methyl cellulose Substances 0.000 description 2
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 2
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
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- 238000009499 grossing Methods 0.000 description 2
- 238000007654 immersion Methods 0.000 description 2
- 239000001034 iron oxide pigment Substances 0.000 description 2
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229920001568 phenolic resin Polymers 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 229920002451 polyvinyl alcohol Polymers 0.000 description 2
- 235000019422 polyvinyl alcohol Nutrition 0.000 description 2
- 230000007420 reactivation Effects 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 238000007788 roughening Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000008107 starch Substances 0.000 description 2
- 235000019698 starch Nutrition 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000000454 talc Substances 0.000 description 2
- 229910052623 talc Inorganic materials 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 229920001634 Copolyester Polymers 0.000 description 1
- XEKOWRVHYACXOJ-UHFFFAOYSA-N Ethyl acetate Chemical compound CCOC(C)=O XEKOWRVHYACXOJ-UHFFFAOYSA-N 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- LEHOTFFKMJEONL-UHFFFAOYSA-N Uric Acid Chemical compound N1C(=O)NC(=O)C2=C1NC(=O)N2 LEHOTFFKMJEONL-UHFFFAOYSA-N 0.000 description 1
- TVWHNULVHGKJHS-UHFFFAOYSA-N Uric acid Natural products N1C(=O)NC(=O)C2NC(=O)NC21 TVWHNULVHGKJHS-UHFFFAOYSA-N 0.000 description 1
- 238000007754 air knife coating Methods 0.000 description 1
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- 238000005266 casting Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
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- 239000003822 epoxy resin Substances 0.000 description 1
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- 239000002657 fibrous material Substances 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- CGXBXJAUUWZZOP-UHFFFAOYSA-N formaldehyde;phenol;1,3,5-triazine-2,4,6-triamine Chemical compound O=C.OC1=CC=CC=C1.NC1=NC(N)=NC(N)=N1 CGXBXJAUUWZZOP-UHFFFAOYSA-N 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 239000001023 inorganic pigment Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000012860 organic pigment Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 229920000193 polymethacrylate Polymers 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 150000004760 silicates Chemical class 0.000 description 1
- 125000005624 silicic acid group Chemical class 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000010345 tape casting Methods 0.000 description 1
- 229940116269 uric acid Drugs 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/502—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording characterised by structural details, e.g. multilayer materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/06—Layered products comprising a layer of paper or cardboard specially treated, e.g. surfaced, parchmentised
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/20—Macromolecular organic compounds
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/20—Macromolecular organic compounds
- D21H17/33—Synthetic macromolecular compounds
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/72—Coated paper characterised by the paper substrate
- D21H19/76—Coated paper characterised by the paper substrate the substrate having specific absorbent properties
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/80—Paper comprising more than one coating
- D21H19/84—Paper comprising more than one coating on both sides of the substrate
Definitions
- the invention relates to a method for producing a flat, printed component, in particular for floor, wall, ceiling and/or furniture applications, a resin-coated paper layer printed with a layer of paint being applied to a flat base body of the component under the influence of pressure and heat , wherein the paper layer is not completely resin-impregnated and wherein the surface of the paper layer is at least partially, preferably at least essentially, resin-free.
- a method for producing a flat, printed component of the type mentioned, a paper web or layer that can be used for this, and a printed flat component of the type mentioned above are from EP 1 749 676 A1 known.
- the EP 1 749 676 A1 specifically relates to a method and a device for producing a paper web that can be printed by means of an inkjet printing method and an object that can be printed by means of this method.
- the object can be plates or panels.
- the aim is to provide an inkjet printing process, in which the print result on the surface of the objects to be printed meets the highest quality requirements in terms of appearance.
- the prior art provides that a paper web that is absorbent for liquid synthetic resin along its entire thickness is soaked with liquid synthetic resin from one side in such a way that the synthetic resin does not completely penetrate the paper web, so that the other side of the paper web is at least largely free of resin is.
- the known method is intended to create surfaces which, with regard to the properties required for printing, correspond to conventional paper surfaces, which should be optimally adapted to the desired printing result through the selection of the paper and the dye liquid.
- the object of the present invention is to remedy this.
- the invention provides in a method of the type mentioned that the applied color layer is dried during printing by means of at least one heating device, that the heating temperature is between 30° C. and 150° C., so that immediate drying of applied ink, wherein the ink contains water and the heating device is an infrared, in particular NIR, and/or a microwave heating device, and that the paper layer is short-cycle pressing with the base body and a protective layer, which is also coated with resin and applied to the color layer , is pressed, the temperature during pressing being between 140°C and 200°C.
- the paper layer is not completely resin-impregnated, the surface of the paper layer being at least partially, preferably at least essentially, resin-free, and a separate ink receiving layer lying on the paper layer being applied to the upper side of the paper layer, which is provided for applying the color layer.
- a separate ink receiving layer lying on the paper layer being applied to the upper side of the paper layer, which is provided for applying the color layer.
- the ink receiving layer which lies on the paper layer and/or is provided at least on the upper side in the paper layer, initially absorbs the ink layer during printing, so that the ink does not come into direct contact with the fibers of the paper layer.
- the thickness of the ink-receptive layer is preferably matched to the ink density and/or the water content of the ink layer in such a way that the printing ink can penetrate the ink-receptive layer and reach the upper area of the paper layer, but does not run there.
- the color layer is applied directly to the color receiving layer and not directly to the paper of the paper layer.
- the ink-receptive layer is provided over the entire surface of the entire upper side of the paper layer, with the upper side of the paper layer being completely covered by the ink-receptive layer.
- the paper layer is resinated in a defined manner from the underside in such a way that the upper paper layer area facing the print side extends over a maximum of 30% of the thickness of the paper layer with little or no resin content.
- the upper paper layer region with little or no resin content extends over only a maximum of 20% of the thickness of the paper layer and more preferably over a maximum of 10% of the thickness of the paper layer, each individual value being between 0.1% of the thickness of the paper layer and 30% of the thickness of the Paper layer is possible and expressly provided as essential to the invention.
- the transition from the upper paper layer area to the lower paper layer area is characterized by an abrupt change in the concentration gradient, while the concentration gradient from the underside of the lower paper layer area to its upper side on the one hand and from the underside of the upper paper layer area to its upper side is essentially constant or continuously decreases.
- the aforementioned values for the thickness of the upper paper layer area relate to the not yet pressed state of the paper layer, ie when the paper layer has not yet been applied to the base body of the component under the influence of pressure and heat.
- An upper protective layer which is also coated with resin, is usually applied to a printed component, at least when it is used in the floor area, under the influence of pressure and heat.
- an essentially resin-free layer region remains between the resin of the protective layer and the resin of the paper layer. Since the resin in the protective layer does not bond with that of the paper layer, or only does so insufficiently, under certain conditions this can lead to the protective layer becoming detached.
- the resin in the protective layer does not bond with that of the paper layer, or only does so insufficiently, under certain conditions this can lead to the protective layer becoming detached.
- it has been recognized that a sufficient connection of the resin of the paper layer with that of the protective layer is guaranteed if the upper paper layer area with little or no resin content extends over a maximum of 30% of the thickness of the paper layer.
- the amount of resin added to the underside is controlled in a defined process-technical manner depending on the porosity and thus the absorbency of the paper layer and the viscosity of the resin. If the resin is applied, for example, using a roller that runs through an immersion bath, with the paper layer being stirred with the underside over a roller, other process parameters include the immersion depth of the roller, the surface finish of the roller, the diameter of the roller, the contact pressure between of the paper layer and the roller and the transport speed of the paper layer play a role. It goes without saying that resin can also be applied to the paper layer in other ways, for example by jet application.
- the paper layer In order to achieve a defined layer thickness of the upper paper layer area, it is also advisable for the paper layer to be soaked from the top with a barrier liquid that does not mix with the resin in such a way that a barrier layer results over a maximum of 30% of the thickness of the paper layer forms for the resin.
- the sealing liquid can be applied in the same way as the resin, but also in a fundamentally different way.
- the barrier liquid After the paper layer has been resinated, the barrier liquid is evaporated. The space originally occupied by the barrier liquid then forms the top paper layer area.
- the invention since the invention is not limited to a defined layer thickness of the resin layer, it goes without saying that it is fundamentally also possible to add the barrier liquid in such a way that ultimately no defined barrier layer is produced.
- the pigments can be white pigments, such as kaolin, calcium carbonate, aluminum hydroxide, talc, titanium dioxide, or color pigments, such as iron oxide pigments, carbon black, copper, aluminum, or other metal pigments, or organic color pigments.
- white pigments such as kaolin, calcium carbonate, aluminum hydroxide, talc, titanium dioxide, or color pigments, such as iron oxide pigments, carbon black, copper, aluminum, or other metal pigments, or organic color pigments.
- liquid dyes and/or silicic acids and/or silicic sols can also be provided.
- binders such as starch, polyvinyl alcohol, carboxymethyl cellulose, polymer dispersions based on acrylic acid, acrylic ester, styrene, butadiene, vinyl acetate or acrylonitrile can be provided.
- Solids of this type support the fixing of the printing ink in the upper paper layer area should the applied printing ink get through the ink-receiving layer.
- the ink-receiving layer at least when it is a pigment coat, can contain all of the aforementioned solids alone or in any combination.
- the ink-receiving layer is applied in connection with or subsequent to impregnation with barrier liquid.
- the ink receiving layer can be applied separately or together with the barrier liquid by rolling, spraying, knife coating, blade coating, air knife coating, cast coating, film pressing, size pressing, curtain casting and/or slot die application.
- the barrier layer can also be formed exclusively by particles of the ink receiving layer.
- the invention also offers the possibility that the paper layer is printed with the ink-receiving layer before it is applied to the base body. It is thus possible on the one hand, after the paper has been produced, which may have been partly resinated in a defined manner, to first print it and to store the paper after printing, for example on rolls or on sheets. The printed paper layer can then be pressed with the base body of the component under the influence of pressure and heat, with the resin first melting and then curing immediately.
- the method according to the invention is suitable for use in so-called direct coating using the short-cycle pressing method.
- the partially resin-coated paper layer hardens directly on the base plate under pressure and heat.
- the base body, as the carrier plate it is essential in the short-cycle pressing process that the base body, as the carrier plate, must yield only insignificantly to the pressing pressure, which is generally between 200 and 650 N/cm 2 .
- the base body and the layers of paper to be applied must not touch the hot press plates during loading and unloading.
- the temperature during pressing is between 140°C and 200°C. Each temperature depends on the reactivation temperature of the resin.
- the so-called critical waiting time i.e. the time from the first contact of the resin-impregnated paper layer with the pressing plate until the necessary pressing pressure is reached, must be observed. This critical idle time should be extremely short.
- the paper layer is preferably printed by means of a digital printing method, in particular an inkjet printing method.
- a digital printing method in particular an inkjet printing method.
- inkjet digital printers are preferably used here, with which excellent printing results can be achieved.
- decorations can be designed in a simple, computer-aided manner and can be printed at short notice.
- the paper layer in contrast to the gravure printing process, it is also possible for the paper layer to be printed only after the resin has been applied.
- Inks containing solvents and/or inks containing water are preferably used for printing.
- UV-based color systems can also be used.
- these have the disadvantage of developing an odor.
- problems can arise when pressing.
- aqueous inks are used.
- the invention provides that the ink layer applied to the paper layer or the ink-receptive layer is heated or dried with an appropriate heating device.
- an appropriate heating device This can be done, for example, via appropriate blowers.
- infrared and, in particular, NIR heating devices and/or microwave heating devices are provided, which act directly on the water content in the paint layer.
- the heating or drying can take place during and/or after the printing. According to the invention, the drying takes place during the printing.
- One or more heaters can be provided for this purpose, with the drying section not only being provided selectively but also extending over a larger area, for example between 0 and 5 m and in particular between 0 and 2 m depends on the reactivation temperature of the resin and is
- the aforesaid heating results in instantaneous drying of the ink and, at best, instantaneous drying of the ink on the ink receiving layer as soon as the ink is discharged from the printhead. Because the heating or drying is of independent inventive importance, partial resin application with a separate ink receiving layer is a preferred embodiment.
- the resination takes place after the actual paper production.
- the resin application can be done with just one resin or optionally in several resin application steps with different resins in order to achieve specific properties of the paper layer.
- the paper layer can be dried and then the ink receiving layer can be applied. This can be followed again by drying.
- a so-called wet/wet treatment takes place.
- the color receiving layer is applied. This can be done simultaneously or sequentially. Subsequently, the resin-impregnated paper layer provided with the ink-receiving layer is dried together.
- the paper layer After drying, the paper layer is either cut into sheets or rolled up as a continuous web. In principle, it is also possible with the method according to the invention for the printing to take place before the cutting/rolling up.
- the paper layer itself can be partially resinated over its thickness in such a way that the upper side of the paper layer is at least partially, preferably at least essentially, resin-free, with a separate ink receiving layer being applied to the upper side of the paper layer, which rests on the paper layer and/or at least on the upper side into the Paper layer has penetrated and on which the color layer is applied during printing.
- the ink-receptive layer has relatively good barrier properties against aqueous or solvent-based substances such as paints and/or printing ink, ie keeps a large part of the ink away from the paper material of the paper layer even with high ink density and/or a high water content.
- the ink-receptive layer usually leads to an equalization of the printed side, which in turn promotes the positive printing result.
- the ink-receiving layer is designed in such a way that the resin can pass through the ink-receiving layer from its underside, particularly during compression.
- the ink-receiving layer preferably covers the entire surface and is designed as a layer that completely covers the upper side of the paper layer. It preferably has a basis weight of between 0.5 g/m 2 and 20 g/m 2 .
- the color receiving layer is in the form of a pigment coating and has organic and/or inorganic pigments and/or binders.
- the pigment coat preferably has white pigments, such as kaolin, calcium carbonate, aluminum hydroxide, talc, titanium dioxide, or color pigments, such as iron oxide pigments, carbon black, copper, aluminum, other metal pigments, or organic color pigments.
- the pigment coating can also contain liquid dyes and/or silica and/or silica sols.
- the pigment coating can contain natural or synthetic binders such as starch, polyvinyl alcohol, carboxymethyl cellulose, polymer dispersions based on acrylic acid, acrylic ester, styrene, butadiene, vinyl acetate or acrylonitrile.
- the ratio of pigment to binder in the pigment coat is preferably from 1:0.05 to 1:1 and in particular from 1:0.08 to 1:0.35, based on the solids content.
- the ink-receptive layer is formed from an ink-receptive composition that has particles with an average diameter of ⁇ 1000 nm. Average diameters of between 50 nm and 400 nm, in particular between 100 nm and 300 nm and preferably between 150 nm and 250 nm, are preferably provided.
- the fibers of the fiber structure of the paper layer are at least essentially encased by such small particles in the top area of the fibrous structure or paper layer, with open interstices of the encased fiber structure remaining on the upper side of the paper layer.
- a plurality of open interstices with a length >20 ⁇ m, preferably >30 ⁇ m and in particular >40 ⁇ m and/or an opening area >200 ⁇ m 2 , preferably >500 ⁇ m 2 and in particular >750 ⁇ m 2 are provided on top of the paper layer.
- at least one gap preferably more than three and in particular more than ten gaps are provided on the upper side per unit area [mm 2 ].
- the particles of the ink-receptive layer/compound can not only consist of the above-mentioned substances, but also in particular have titanium dioxide, barium sulfate and silicates as main components.
- the top paper layer portion of the paper layer has little or no resin content.
- the thickness of the upper paper layer area can be arbitrary, in order to avoid the "blotter effect" it is favorable if this area extends over a maximum of 30% of the thickness of the paper layer, with any value between 0.01% and 30% being possible and essential to the invention . It goes without saying that the material and the porosity of the paper layer are selected in such a way that partial penetration of the paper layer by resin and optionally the already mentioned barrier liquid is possible.
- the aforementioned barrier liquid when applied in conjunction with the ink receiving layer, there may be solids such as pigments and/or binders embedded in the top paper layer area. These solids can then correspond to the materials that are also contained in the ink-receptive layer.
- the weight per unit area of the paper layer without resin content should be between 30 and 300 g/m 2 , preferably between 50 and 120 g/m 2 .
- the basis weight of the resin portion should preferably be between 5 and 300 g/m 2 and in particular between 20 and 100 g/m 2 .
- the resin itself is a reactivatable resin, in particular an aminoplast such as a melamine resin.
- Resins from the group of diallyl phthalates, epoxy resins, urea-formaldehyde resins, uric acid acetyl ester copolyesters, melamine-formaldehyde resins, melamine-phenol-formaldehyde resins, phenol-formaldehyde resins, poly(meth)acrylates or unsaturated resins are preferred Polyester resins used.
- the upper side of the ink receiving layer is smoothed, sanded and/or finely roughened before or after the resin application, preferably by additional mechanical processing following paper production, for example using a squeegee or calender, in order to prevent any unintentional running of the printing ink.
- ranges and intervals mentioned above and below include all individual values and intermediate intervals or intermediate ranges within the ranges and intervals without the need for an express mention of individual values or intermediate intervals or intermediate ranges.
- a paper layer 1 is shown.
- the paper layer 1 consists of a conventional absorbent or liquid-absorbent paper or fiber material.
- the paper layer 1 as such can be part of a roll or a sheet.
- In 1 is shown schematically that the paper layer 1 is resinated only over part of its thickness d. This results in an upper paper layer area 3 facing the top 2 with little or no resin content and a lower paper layer area 4 which starts from the underside 5 and has a very high resin content.
- the state shown shows ideal conditions, with the upper paper layer area 3 being resin-free, while the lower paper layer area 4 is completely resin-impregnated.
- the transition between the two areas 3, 4 at point x is illustrated by a dashed line.
- the inside 1 The state shown, ie the clear separation between the areas 3 and 4 is such that no resin is provided in the upper paper layer area 3, while the lower paper layer area 4 is completely resinated, is extremely difficult to achieve.
- 2 shows a state approximate to actual conditions in a diagram.
- the concentration c is plotted as a percentage on the Y axis and the layer thickness d of the paper layer 1 is also plotted as a percentage on the X axis, the layer thickness d beginning at the bottom 5 and ending at the top 2 .
- the upper curve shows the ideal concentration distribution of the resin, with the resin concentration constantly being 100% in the lower paper layer area 4 and abruptly decreasing to 0% at point x, ie at the transition to the upper paper layer area 3 .
- the lower curve shows a greater drop in concentration from the bottom 5 to the transition to the upper paper layer area 3, i.e. up to point x, with the concentration gradient then falling considerably more sharply, i.e. the gradient of the concentration drop is still at least more than double is as great as in the lower paper layer area 4.
- the course of the concentration gradient depends on the respective application parameters, in particular the porosity or absorbency of the paper layer 1 and the viscosity of the resin and the process parameters when applying the resin to the underside 5.
- the upper paper layer area 3 and the lower paper layer area 4 are characterized in that the drop in concentration of the resin content in the upper paper layer area 3 is at least a factor of 2 greater than in the lower paper layer area 4. It goes without saying that the drop in concentration is much greater than the can be a factor of 2, as in particular the ideal curve in 3 proven. Ultimately, any individual value from a factor of 2 and above a factor of 2 is possible.
- the upper paper layer region 3 extends over a maximum of 30% of the thickness d of the paper layer 1. in the in Figures 2 and 3 illustrated applications makes the upper paper layer area 3 about 10% to 20% of the thickness d of the paper layer 1. In all applications it is the case that there is no or only a very small proportion of resin on the pressure side 2 .
- the optimal extension of the upper paper layer area 3 is between 3% and 20% of the thickness d of the paper layer 1. Depending on the nature of the paper and the printing ink used, this results in an optimal printing result, since the printing ink ultimately covers only a very small area of the paper layer 1 can be picked up and not run away.
- the present invention is not limited to the Figures 2 and 3 shown concentration gradient is limited.
- the upper paper layer area 3 it is also possible for the upper paper layer area 3 to be greater than 30% and/or for example for a constant concentration gradient from the underside 5 to the upper side 2 of the paper layer 1 to result.
- a separate ink receiving layer 6 lying on the paper layer 1 is provided on the upper side of the paper layer 1, as is shown in 1 is shown, on the upper side 7, as in 4 is shown, a color layer 8 is applied.
- the top 7 of the ink receiving layer 6 thus forms the print side.
- the color receiving layer 6 ultimately avoids direct or immediate contact of the color layer 8 with the top side 2 of the paper layer 1 .
- the ink receiving layer 6 is located over the entire surface of the top 2 of the paper layer 1 and covers it completely.
- the basis weight of the ink receiving layer 6 is usually between 0.5 g/m 2 and 20 g/m 2 .
- the color layer 8 has been applied by means of an inkjet digital printer (not shown), ie by means of the inkjet printing method, although other printing methods, in particular gravure printing, are also possible.
- Water-based inks are used as printing inks.
- a printed flat component 9 is shown in detail.
- the component 9 can in particular be a plate or a panel. It is preferably floor, wall and/or ceiling covering elements or panel-shaped furniture elements.
- the component 9 has a flat base body 10, shown only partially, which can be constructed in one or more layers and consists in particular of wood and/or plastic materials.
- the component 9 can be wood-based panels such as MDF, HDF or DKS panels or so-called HPL (high pressure laminate) panels.
- the component 9 can also be thicker foil, cardboard or plasterboard.
- Component 9 shown is applied to the top 11 of the base body 10, the printed paper layer 1 with ink receiving layer 6 and firmly connected thereto. Furthermore, a protective layer 12 is applied to the color layer 8 .
- the protective layer 12 is generally implemented in components that are used in the floor area. In principle, however, the protective layer 12 can also be dispensed with. This applies in particular to wall and ceiling applications and furniture elements. According to the invention, a protective layer is provided.
- the method according to the invention is shown schematically in a short-cycle pressing method.
- the method begins with the known production of the paper in a paper machine, which is shown in method step 11.
- the paper layer 1 is still part of a virtually endless paper web.
- the (defined) partial resin application of the paper layer 1 from the underside 5 takes place in process step 14 in such a way that the lower paper layer area makes up about 85% of the thickness d of the paper layer 1, while the upper paper layer area 3 then makes up about 15%. up to 20% of the thickness.
- the defined partial resin application can be produced in method step 14 in that the sheet-like paper layer 1, after it has been produced, is guided with its underside 5 over or past a rotatable roller which is immersed in liquid resin.
- the above-described partial resin application from the underside 5 is basically sufficient to obtain an upper paper layer area 3 that is relatively narrow compared to the lower paper layer area 4, it can basically also be advisable that immediately before the partial resin application on the pressure side 2 of the paper layer 1 Barrier liquid is applied defined, which penetrates into the paper layer 1, thereby forming a barrier layer for the resin.
- the thickness of the barrier layer essentially corresponds to the thickness of the later upper paper layer area 3. It is important that the barrier liquid does not mix with the resin.
- the paper layer 1 is then heated so that the barrier liquid evaporates. In this context, it may be advisable to provide solids in the barrier liquid, which remain in the upper paper layer area 3 after evaporation.
- the ink receiving layer 6 can be applied with the desired layer thickness or the desired weight per unit area.
- the ink receiving layer is applied directly after paper production, ie the production of a paper web, and is then resinated in the next process step.
- the ink-receptive layer 6 can also be applied to the top side 2 of the paper layer 2 together with the barrier liquid, the barrier liquid then being evaporated and the ink-receptive layer 6 remaining.
- the ink receiving layer 6 can also be applied only after the partial resin application.
- the printing takes place in the inkjet printing process using an inkjet digital printer.
- the paper layer 1 can still be part of a paper web or already part of a sheet cut off from the paper web. Cutting to sheets can also be done later.
- Process step 16 namely the heating of the print side and thus the drying of the ink layer 6 directly after application to the ink receiving layer 6, is carried out parallel to process step 15.
- the paper layer 1 with the ink receiving layer 6 can in principle also have been heated before printing, so that the ink already impinges on a preheated paper layer 1 during printing, which supports drying. According to the invention, drying must take place during printing.
- the paper layer 1 is pressed with the base body 10 in a corresponding pressing device.
- the protective layer 12 is pressed.
- the resin in the paper layer 1 and the resin in the protective layer 12 melts and hardens immediately during the pressing process, so that on the one hand a firm connection of the paper layer 1 to the base body 10 and on the other hand a firm connection of the protective layer 12 on the paper layer 1 results.
- th is applied to the base body 10, but still without a protective layer 12, by pressing in the pressing device mentioned.
- FIG 7 a non-inventive short-cycle pressing method of direct coating is shown schematically.
- the method steps 18 and 19 correspond to the previously mentioned method steps 13 and 14 of paper production and partial resin application. This is followed, however, by process step 20, in which the paper layer 1 with the ink receiving layer 6, already cut into sheets, is applied to the base body 10, but still without a protective layer 12, by pressing in the pressing device mentioned.
- the unprinted component 9 is now also printed in method step 21 using the inkjet printing method. Parallel to this or immediately afterwards, the applied ink layer 8 is dried in method step 22. Of course, the paper layer 1 or the ink-receiving layer 6 can also have been preheated here. This is followed by the pressing of the protective layer 12 in the pressing device in method step 23 in order to connect the protective layer 12 to the paper layer 1 after the resin in the protective layer 12 has melted and hardened.
Landscapes
- Ink Jet (AREA)
- Laminated Bodies (AREA)
- Ink Jet Recording Methods And Recording Media Thereof (AREA)
- Paper (AREA)
Abstract
Description
Die Erfindung betrifft ein Verfahren zum Herstellen eines flächigen, bedruckten Bauteils, insbesondere für Boden-, Wand-, Decken- und/oder Möbelanwendungen, wobei auf einen flächigen Grundkörper des Bauteils eine beharzte, mit einer Farbschicht bedruckte Papierschicht unter Druck- und Hitzeeinfluß aufgebracht wird, wobei die Papierschicht nicht vollständig durchbeharzt ist und wobei die Oberfläche der Papierschicht zumindest teilweise, vorzugsweise zumindest im wesentlichen harzfrei ist.The invention relates to a method for producing a flat, printed component, in particular for floor, wall, ceiling and/or furniture applications, a resin-coated paper layer printed with a layer of paint being applied to a flat base body of the component under the influence of pressure and heat , wherein the paper layer is not completely resin-impregnated and wherein the surface of the paper layer is at least partially, preferably at least essentially, resin-free.
Ein Verfahren zum Herstellen eines flächigen, bedruckten Bauteils der eingangs genannten Art, eine dafür verwendbare Papierbahn oder -schicht sowie ein bedrucktes flächiges Bauteil der zuvor genannten Art sind aus der
Bei der
Durch das bekannte Verfahren sollen Oberflächen geschaffen werden, die hinsichtlich ihrer für das Bedrucken erforderlichen Eigenschaften konventionellen Papieroberflächen entsprechen, die durch die Auswahl des Papiers und der Färbeflüssigkeitoptimal an das angestrebte Druckergebnis angepaßt sein sollen.The known method is intended to create surfaces which, with regard to the properties required for printing, correspond to conventional paper surfaces, which should be optimally adapted to the desired printing result through the selection of the paper and the dye liquid.
Allerdings ist im Zusammenhang mit der aus der
Aufgabe der vorliegenden Erfindung ist es, hier Abhilfe zu schaffen.The object of the present invention is to remedy this.
Zur Lösung der zuvor genannten Aufgabe ist bei einem Verfahren der eingangs genannten Art erfindungsgemäß vorgesehen, daß die aufgebrachte Farbschicht während dem Drucken mittels wenigstens einer Heizeinrichtung getrocknet wird, daß die Heiztemperatur zwischen 30°C und 150°C liegt, so daß sich eine unmittelbare Trocknung von aufgebrachter Tinte ergibt, wobei die Tinte wasserhaltig ist und die Heizeinrichtung eine Infrarot-, insbesondere NIR-, und/oder eine Mikrowellenheizeinrichtung ist, und daß die Papierschicht im Kurztaktpressverfahren mit dem Grundkörper und einer Schutzschicht, die ebenfalls beharzt und auf die Farbschicht aufgebracht ist, verpresst wird, wobei die Temperatur beim Verpressen zwischen 140°C und 200°C liegt. Gemäß einer bevorzugten Ausführungsform ist es weiterhin vorgesehen, daß die Papierschicht nicht vollständig durchbeharzt ist, wobei die Oberfläche der Papierschicht zumindest teilweise, vorzugsweise zumindest im wesentlichen harzfrei ist, und wobei auf die Oberseite der Papierschicht eine separate, auf der Papierschicht aufliegende Farbaufnahmeschicht aufgebracht wird, die zum Aufbringen der Farbschicht vorgesehen ist. Im Zusammenhang mit der vorliegenden Erfindung ist festgestellt worden, daß sich hervorragende Druckergebnisse insbesondere dann erzielen lassen, wenn einerseits ein nicht vollständig durchbeharztes Papier und andererseits ein vorzugsweise relativ dünne Farbaufnahmeschicht vorgesehen sind. Die Farbaufnahmeschicht, die auf der Papierschicht aufliegt und/oder zumindest oberseitig in der Papierschicht vorgesehen ist, nimmt zunächst die Farbschicht beim Bedrucken auf, so daß die Tinte nicht unmittelbar in Kontakt mit den Fasern der Papierschicht kommt. Bevorzugt ist die Dicke der Farbaufnahmeschicht auf die Farbdichte und/oder den Wasseranteil der Farbschicht dahingehend abgestimmt, daß die Druckfarbe zwar die Farbaufnahmeschicht durchdringen und bis in den oberen Bereich der Papierschicht gelangen kann, dort jedoch nicht verläuft. Anders als bei dem aus der
Damit der erfindungsgemäße Vorteil an jeder Stelle der Papierschicht erzielt werden kann, ist die Farbaufnahmeschicht vollflächig auf der gesamten Oberseite der Papierschicht vorgesehen, wobei die Oberseite der Papierschicht vollständig von der Farbaufnahmeschicht abgedeckt wird.So that the advantage according to the invention can be achieved at every point of the paper layer, the ink-receptive layer is provided over the entire surface of the entire upper side of the paper layer, with the upper side of the paper layer being completely covered by the ink-receptive layer.
Wenngleich es grundsätzlich möglich ist, die separate Farbaufnahmeschicht nach der vorliegenden Erfindung unmittelbar auf einer solchen teilbeharzten Papierbahn vorzusehen, wie sie aus der
Hinzuweisen ist in diesem Zusammenhangdarauf, daß sich zwischen dem oberen Papierschichtbereich mit geringem oder ohne Harzanteil und dem unteren Papierschichtbereich mit hohem Harzanteil in der Praxis keine exakte Trennlinie ergibt, da bei einer Beharzung von unten her ein Konzentrationsgefälle des Harzes von unten nach oben besteht derart, daß die höchste Konzentration an der Unterseite vorliegt. Der Übergang des oberen Papierschichtbereichs zum unteren Papierschichtbereich zeichnet sich jedoch durch eine abrupte Änderung des Konzentrationsgefälles aus, während das Konzentrationsgefälle von der Unterseite des unteren Papierschichtbereichs zu dessen Oberseite einerseits und von der Unterseite des oberen Papierschichtbereichs dessen Oberseite im wesentlichen konstant ist oder kontinuierlich abnimmt. Im übrigen beziehen sich die vorgenannten Werte der Dicke des oberen Papierschichtbereichs auf den noch nicht verpreßten Zustand der Papierschicht, also wenn die Papierschicht noch nicht auf den Grundkörper des Bauteils unter Druck- und Hitzeeinfluß aufgebracht worden ist.It should be pointed out in this context that between the upper paper layer area with little or no resin content and the lower paper layer area with a high resin content does not result in an exact dividing line in practice, since when resin is applied from below there is a concentration gradient of the resin from bottom to top such that the highest concentration is on the underside. However, the transition from the upper paper layer area to the lower paper layer area is characterized by an abrupt change in the concentration gradient, while the concentration gradient from the underside of the lower paper layer area to its upper side on the one hand and from the underside of the upper paper layer area to its upper side is essentially constant or continuously decreases. The aforementioned values for the thickness of the upper paper layer area relate to the not yet pressed state of the paper layer, ie when the paper layer has not yet been applied to the base body of the component under the influence of pressure and heat.
Darüber hinaus ergibt sich bei der zuvor erwähnten definierten Teilbeharzung ein weiterer, durchaus beachtlicher Vorteil. Üblicherweise wird auf ein bedrucktes Bauteil, jedenfalls wenn es im Bodenbereich eingesetzt wird, eine obere Schutzschicht, die ebenfalls beharzt ist, unter Druck- und Hitzeeinfluß aufgebracht. Bei dem aus der
Zur Erzielung einer definierten Harzschichtdickein der Papierschicht wird die Menge des der Unterseite zugeführten Harzanteils in Abhängigkeit der Porosität und damit der Saugfähigkeit der Papierschicht und der Viskosität des Harzes verfahrenstechnisch definiert gesteuert. Wird die Beharzung beispielsweise über eine Walze, die durch ein Tauchbad läuft, wobei die Papierschicht mit der Unterseite über eine Walze gerührt wird, vorgenommen, spielen als weitere Prozeßparameter die Eintauchtiefe der Walze, die Oberflächenbeschaffenheit der Walze, der Durchmesser der Walze, der Anpreßdruck zwischen der Papierschicht und der Walze und die Transportgeschwindigkeit der Papierschicht eine Rolle. Es versteht sich, daß Harz auch in anderer Weise auf die Papierschicht aufgebracht werden kann, beispielsweise durch Düsenauftrag.In order to achieve a defined resin layer thickness in the paper layer, the amount of resin added to the underside is controlled in a defined process-technical manner depending on the porosity and thus the absorbency of the paper layer and the viscosity of the resin. If the resin is applied, for example, using a roller that runs through an immersion bath, with the paper layer being stirred with the underside over a roller, other process parameters include the immersion depth of the roller, the surface finish of the roller, the diameter of the roller, the contact pressure between of the paper layer and the roller and the transport speed of the paper layer play a role. It goes without saying that resin can also be applied to the paper layer in other ways, for example by jet application.
Zur Erzielung einer definierten Schichtdicke des oberen Papierschichtbereichs bietet es sich im übrigen an, daß die Papierschicht von der Oberseite her definiert mit einer sich nicht mit dem Harz mischenden Sperrflüssigkeit getränkt wird derart, daß sich eine sich über maximal 30% der Dicke der Papierschicht ergebende Sperrschicht für das Harz bildet. Die Aufbringung der Sperrflüssigkeit kann in gleicher Weise wie die Aufbringung des Harzes aber auch grundsätzlich in anderer Weise erfolgen. Nach dem Beharzen der Papierschicht wird die Sperrflüssigkeit verdampft. Der ursprünglich von der Sperrflüssigkeit eingenommene Raum bildet dann den oberen Papierschichtbereich. Da die Erfindung allerdings nicht auf eine definierte Schichtdicke der Harzschicht beschränkt ist, versteht es sich, daß es grundsätzlich auch möglich ist, die Sperrflüssigkeit in der Art zuzugeben, daß letztlich keine definierte Sperrschicht erzeugt wird.In order to achieve a defined layer thickness of the upper paper layer area, it is also advisable for the paper layer to be soaked from the top with a barrier liquid that does not mix with the resin in such a way that a barrier layer results over a maximum of 30% of the thickness of the paper layer forms for the resin. The sealing liquid can be applied in the same way as the resin, but also in a fundamentally different way. After the paper layer has been resinated, the barrier liquid is evaporated. The space originally occupied by the barrier liquid then forms the top paper layer area. However, since the invention is not limited to a defined layer thickness of the resin layer, it goes without saying that it is fundamentally also possible to add the barrier liquid in such a way that ultimately no defined barrier layer is produced.
Bevorzugt ist es in diesem Zusammenhang, daß in der Sperrflüssigkeit nach dem Verdampfen in dem oberen Papierschichtbereich verbleibende Feststoffe, insbesondere Pigmente und/oder Bindemittel vorgesehen sind. Bei den Pigmenten kann es sich um Weißpigmente, wie Kaolin, Kalziumcarbonat, Aluminiumhydroxid, Talkum, Titandioxid oder Farbpigmente, wie Eisenoxidpigmente, Ruß, Kupfer, Aluminium oder andere Metallpigmente, oder organische Farbpigmente handeln. Außerdem können auch Flüssigfarbstoffe und/oder Kieselsäuren und/oder Kieselsole vorgesehen sein. Desweiteren können natürliche oder synthetische Bindemittel, wie Stärke, Polyvinylalkohol, Carboxymethyzellulose, Polymerdispersionen auf der Basis von Acrylsäure, Acrylester, Styrol, Butadien, Vinylacetat oder Acrylnitril vorgesehen sein. Derartige Feststoffe unterstützen die Fixierung der Druckfarbe im oberen Papierschichtbereich, sollte die aufgebrachte Druckfarbe durch die Farbaufnahmeschicht hindurch gelangen. Im übrigen ist darauf hinzuweisen, daß die Farbaufnahmeschicht, jedenfalls wenn es sich hierbei um einen Pigmentstrich handelt, sämtliche der vorgenannten Feststoffe für sich oder in beliebiger Kombination aufweisen kann.It is preferred in this connection that solids, in particular pigments and/or binders, remaining in the sealing liquid after evaporation in the upper paper layer region are provided. The pigments can be white pigments, such as kaolin, calcium carbonate, aluminum hydroxide, talc, titanium dioxide, or color pigments, such as iron oxide pigments, carbon black, copper, aluminum, or other metal pigments, or organic color pigments. In addition, liquid dyes and/or silicic acids and/or silicic sols can also be provided. Furthermore, natural or synthetic binders such as starch, polyvinyl alcohol, carboxymethyl cellulose, polymer dispersions based on acrylic acid, acrylic ester, styrene, butadiene, vinyl acetate or acrylonitrile can be provided. Solids of this type support the fixing of the printing ink in the upper paper layer area should the applied printing ink get through the ink-receiving layer. Moreover, it should be pointed out that the ink-receiving layer, at least when it is a pigment coat, can contain all of the aforementioned solids alone or in any combination.
Im übrigen bietet es sich an, wenn die Farbaufnahmeschicht in Verbindung oder im Anschluß an das Tränken mit Sperrflüssigkeit aufgebracht wird. Die Farbaufnahmeschicht kann separat oder zusammen mit der Sperrflüssigkeit durch Walzen, Sprühen, Rakeln, Blade-Coating, Luftbürsten, Gußstrich-Verfahren, Filmpressen, Leimpressen, Vorhanggießverfahren und/oder durch Schlitzdüsenauftrag aufgebracht werden. Grundsätzlich kann die Sperrschicht auch ausschließlich durch Partikel der Farbaufnahmeschicht gebildet sein.It is also advisable if the ink-receiving layer is applied in connection with or subsequent to impregnation with barrier liquid. The ink receiving layer can be applied separately or together with the barrier liquid by rolling, spraying, knife coating, blade coating, air knife coating, cast coating, film pressing, size pressing, curtain casting and/or slot die application. In principle, the barrier layer can also be formed exclusively by particles of the ink receiving layer.
Die Erfindung bietet im übrigen die Möglichkeit, daß die Papierschicht mit der Farbaufnahmeschicht vor dem Aufbringen auf den Grundkörper bedruckt wird. So ist es zum einen möglich, nach Herstellen des gegebenenfalls definiert teilbeharzten Papiers dieses zunächst zu bedrucken und das Papier nach dem Bedrucken zu bevorraten, beispielsweise auf Rollen oder auf Bögen. Anschließend kann die bedruckte Papierschicht mit dem Grundkörper des Bauteils unter Druck- und Hitzeeinfluß verpreßt werden, wobei das Harz zunächst aufschmilzt und anschließend unmittelbar aushärtet.The invention also offers the possibility that the paper layer is printed with the ink-receiving layer before it is applied to the base body. It is thus possible on the one hand, after the paper has been produced, which may have been partly resinated in a defined manner, to first print it and to store the paper after printing, for example on rolls or on sheets. The printed paper layer can then be pressed with the base body of the component under the influence of pressure and heat, with the resin first melting and then curing immediately.
Das erfindungsgemäße Verfahren eignet sich bei der Anwendung in der sogenannten Direktbeschichtung durch das Kurztaktpreßverfahren. Hierbei härtet die teilbeharzte Papierschicht direkt auf der Grundplatte unter Druck und Hitze schmelzend aus. Wesentlich beim Kurztaktpreßverfahren ist zunächst, daß der Grundkörper als Trägerplatte dem Preßdruck, der in der Regel zwischen 200 und 650 N/cm2 liegt, nur unwesentlich nachgeben darf. Darüber hinaus dürfen die Grundkörper und die aufzubringenden Papierschichten beim Ein- und Austrag die heißen Preßplatten nicht berühren. Die Temperatur beim Verpressen liegt zwischen 140°C und 200°C. Je jeweilige Temperatur ist abhängig von der Reaktivierungstemperatur des Harzes. Schließlich ist die sogenannte kritische Liegezeit, das heißt die Zeit vom ersten Kontakt der beharzten Papierschicht mit der Preßplatte bis zum Erreichen des notwendigen Preßdruckes, zu beachten. Diese kritische Liegezeit sollte extrem kurz sein.The method according to the invention is suitable for use in so-called direct coating using the short-cycle pressing method. Here, the partially resin-coated paper layer hardens directly on the base plate under pressure and heat. First of all, it is essential in the short-cycle pressing process that the base body, as the carrier plate, must yield only insignificantly to the pressing pressure, which is generally between 200 and 650 N/cm 2 . In addition, the base body and the layers of paper to be applied must not touch the hot press plates during loading and unloading. The temperature during pressing is between 140°C and 200°C. Each temperature depends on the reactivation temperature of the resin. Finally, the so-called critical waiting time, i.e. the time from the first contact of the resin-impregnated paper layer with the pressing plate until the necessary pressing pressure is reached, must be observed. This critical idle time should be extremely short.
Wenngleich es grundsätzlich möglich ist, das erfindungsgemäße Verfahren in Verbindung mit allen bekannten Druckverfahren, insbesondere auch dem Tiefdruckverfahren anzuwenden, erfolgt die Bedruckung der Papierschicht vorzugsweise mittels eines digitalen Druckverfahrens, insbesondere eines Tintenstrahldruckverfahrens. Hierbei kommen dann vorzugsweise sogenannte Inkjet-Digitaldrucker zum Einsatz, mit denen sich hervorragende Druckergebnisse erzielen lassen. Darüber hinaus lassen sich - anders als beim Tiefdruckverfahren - Dekore in einfacher Weise rechnergestützt entwerfen und können kurzfristig gedruckt werden. Im übrigen ist es im Unterschied zum Tiefdruckverfahren auch möglich, daß die Papierschicht erst nach dem Beharzen bedruckt wird.Although it is fundamentally possible to use the method according to the invention in connection with all known printing methods, in particular also the intaglio printing method, the paper layer is preferably printed by means of a digital printing method, in particular an inkjet printing method. So-called inkjet digital printers are preferably used here, with which excellent printing results can be achieved. In addition - in contrast to the gravure printing process - decorations can be designed in a simple, computer-aided manner and can be printed at short notice. Moreover, in contrast to the gravure printing process, it is also possible for the paper layer to be printed only after the resin has been applied.
Zur Bedruckung werden dabei bevorzugt lösemittelhaltige Tinte und/oder wasserhaltige Tinten verwendet. Grundsätzlich können auch UV-basierende Farbsysteme verwendet werden. Diese haben allerdings den Nachteil einer Geruchsentwicklung. Außerdem können sich Probleme beim Verpressen ergeben. Erfindungsgemäss werden wasserhaltige Tinten verwendet.Inks containing solvents and/or inks containing water are preferably used for printing. In principle, UV-based color systems can also be used. However, these have the disadvantage of developing an odor. In addition, problems can arise when pressing. According to the invention, aqueous inks are used.
Um ein etwaiges Verlaufen der Tinte bei hohem Farbauftrag in jedem Falle zu vermeiden, bietet es sich an, die Druckseite und damit die Oberseite der Farbaufnahmeschicht nach der Papierherstellung und auch nach dem Beharzen, jedenfalls aber vor dem Bedrucken zu glätten, zu schleifen und/oder insbesondere fein aufzurauhen. Das Glätten, Schleifen und/oder Aufrauhen kann beispielsweise durch spezielle Rakel oder Kalander erfolgen.In order to avoid any running of the ink when there is a lot of ink applied, it is advisable to smooth, grind and/or smooth the printed side and thus the upper side of the ink receiving layer after paper production and also after resining, but in any case before printing especially finely roughened. The smoothing, grinding and/or roughening can take place, for example, using special squeegees or calenders.
Unabhängig von der Aufbringung der Farbaufnahmeschicht und/oder der Glättung bzw. Aufrauhung der Papierschicht ist es erfindungsgemäß vorgesehen, daß die auf die Papierschicht bzw. die Farbaufnahmeschicht aufgebrachte Farbschicht mit einer entsprechenden Heizeinrichtung beheizt bzw. getrocknet wird. Dies kann beispielsweise über entsprechende Gebläse erfolgen. Erfindungsgemäß sind Infrarot-, und insbesondere NIR-Heizeinrichtungen, und/oder Mikrowellenheizeinrichtungen vorgesehen, die unmittelbar auf den Wasseranteil in der Farbschicht wirken. Die Beheizung bzw. Trocknung kann während und/oder nach dem Bedrucken erfolgen. Erfindungsgemäss erfolgt die Trocknung während dem Bedrucken. Hierzu können ein oder mehrere Heizgeräte vorgesehen sein, wobei die Trocknungsstrecke nicht nur punktuell vorgesehen sein, sondern sich auch über einen größeren Bereich erstrecken kann, beispielsweise zwischen 0 und 5 m und insbesondere zwischen 0 und 2 m. Die Temperatur beim Heizen bzw. Trocknen ist abhängig von der Reaktivierungstemperatur des Harzes und liegtIrrespective of the application of the ink-receptive layer and/or the smoothing or roughening of the paper layer, the invention provides that the ink layer applied to the paper layer or the ink-receptive layer is heated or dried with an appropriate heating device. This can be done, for example, via appropriate blowers. According to the invention, infrared and, in particular, NIR heating devices and/or microwave heating devices are provided, which act directly on the water content in the paint layer. The heating or drying can take place during and/or after the printing. According to the invention, the drying takes place during the printing. One or more heaters can be provided for this purpose, with the drying section not only being provided selectively but also extending over a larger area, for example between 0 and 5 m and in particular between 0 and 2 m depends on the reactivation temperature of the resin and is
zwischen 30°C und 150°C. Die vorgenannte Beheizung führt zu einer unmittelbaren Trocknung der Tinte und führt im besten Falle zu einer unmittelbaren Trocknung der Tinte auf der Farbaufnahmeschicht, sobald die Tinte vom Druckkopf abgegeben wird. Weil der Beheizung bzw. Trocknung eigenständige erfinderische Bedeutung zukommt, ist die Teilbeharzung mit separater Farbaufnahmeschicht eine bevorzugte Ausführungsform.between 30°C and 150°C. The aforesaid heating results in instantaneous drying of the ink and, at best, instantaneous drying of the ink on the ink receiving layer as soon as the ink is discharged from the printhead. Because the heating or drying is of independent inventive importance, partial resin application with a separate ink receiving layer is a preferred embodiment.
Im Zusammenhang mit der Herstellung der Papierschicht ist darauf hinzuweisen, daß nach der eigentlichen Papierherstellung die Beharzung erfolgt. Die Beharzung kann dabei mit nur einem Harz oder gegebenenfalls in mehreren Beharzungsschritten auch mit unterschiedlichen Harzen erfolgen, um bestimmte Eigenschaften der Papierschicht zu erzielen. Nach dem Beharzen kann ein Trocknen der Papierschicht und anschließend das Aufbringen der Farbaufnahmeschicht erfolgen. Hieran kann sich erneut ein Trocknen anschließen. Bei einer alternativen Ausführungsform erfolgt eine sogenannte Naß/Naß-Behandlung. Hierbei wird, bevor das Harz vollständig getrocknet ist, sich also noch in einem flüssigen oder gelierten bzw. angelierten Zustand befindet, die Farbaufnahmeschicht aufgebracht. Dies kann gleichzeitig oder hintereinander erfolgen. Anschließend erfolgt eine gemeinsame Trocknung der beharzten und mit der Farbaufnahmeschicht versehenen Papierschicht.In connection with the production of the paper layer, it should be pointed out that the resination takes place after the actual paper production. The resin application can be done with just one resin or optionally in several resin application steps with different resins in order to achieve specific properties of the paper layer. After resining, the paper layer can be dried and then the ink receiving layer can be applied. This can be followed again by drying. In an alternative embodiment, a so-called wet/wet treatment takes place. In this case, before the resin has completely dried, that is to say is still in a liquid or gelled or gelled state, the color receiving layer is applied. This can be done simultaneously or sequentially. Subsequently, the resin-impregnated paper layer provided with the ink-receiving layer is dried together.
Nach dem Trocknen wird die Papierschicht entweder auf Bögen geschnitten oder aber als durchgehende Bahn aufgerollt. Grundsätzlich ist es beim erfindungsgemäßen Verfahren auch möglich, daß vor dem Schneiden/Aufrollen noch das Bedrucken erfolgt.After drying, the paper layer is either cut into sheets or rolled up as a continuous web. In principle, it is also possible with the method according to the invention for the printing to take place before the cutting/rolling up.
Die Papierschicht kann selbst über ihre Dicke derart teilbeharzt sein, daß die Oberseite der Papierschicht zumindest bereichsweise, vorzugsweise zumindest im wesentlichen harzfrei ist, wobei auf die Oberseite der Papierschicht eine separate Farbaufnahmeschicht aufgebracht ist, die auf der Papierschicht aufliegt und/oder zumindest oberseitig in die Papierschicht eingedrungen ist und auf die die Farbschicht beim Bedrucken aufgebracht wird. Die Farbaufnahmeschicht besitzt relativ gute Barriereeigenschaften gegenüber wäßrigen oder lösemittelhaltigen Substanzen wie Lacken und/oder Druckfarbe, hält also auch bei hoher Farbdichte und/oder hohem Wasseranteil einen Großteil der Tinte vom Papiermaterial der Papierschicht fern. Bei relativ dünnen Farbaufnahmeschichten kann damit auch ein definierter Durchtritt von Druckfarben auf bzw. in die Papierschicht erfolgen. Darüber hinaus führt die Farbaufnahmeschicht in der Regel zu einer Vergleichmäßigung der Druckseite, was wiederum das positive Druckergebnis begünstigt. Im übrigen ist die Farbaufnahmeschicht derart ausgebildet, daß ein Durchtritt des Harzes durch die Farbaufnahmeschicht von ihrer Unterseite her insbesondere beim Verpressen möglich ist.The paper layer itself can be partially resinated over its thickness in such a way that the upper side of the paper layer is at least partially, preferably at least essentially, resin-free, with a separate ink receiving layer being applied to the upper side of the paper layer, which rests on the paper layer and/or at least on the upper side into the Paper layer has penetrated and on which the color layer is applied during printing. The ink-receptive layer has relatively good barrier properties against aqueous or solvent-based substances such as paints and/or printing ink, ie keeps a large part of the ink away from the paper material of the paper layer even with high ink density and/or a high water content. In the case of relatively thin ink receiving layers, a defined passage of printing inks onto or into the paper layer can also take place. In addition, the ink-receptive layer usually leads to an equalization of the printed side, which in turn promotes the positive printing result. Moreover, the ink-receiving layer is designed in such a way that the resin can pass through the ink-receiving layer from its underside, particularly during compression.
Die Farbaufnahmeschicht ist vorzugsweise vollflächig und als auf die Oberseite der Papierschicht vollständig abdeckende Schicht ausgebildet. Sie weist dabei vorzugsweise ein Flächengewicht zwischen 0,5 g/m2 und 20 g/m2 auf.The ink-receiving layer preferably covers the entire surface and is designed as a layer that completely covers the upper side of the paper layer. It preferably has a basis weight of between 0.5 g/m 2 and 20 g/m 2 .
Bei einer bevorzugten Ausführungsform der Erfindung ist die Farbaufnahmeschicht als Pigmentstrich ausgebildet und weist organische und/oder anorganische Pigmente und/oder Bindemittel auf. Bevorzugt weist der Pigmentstrich Weißpigmente, wie Kaolin, Kalziumcarbonat, Aluminiumhydroxid, Talkum, Titandioxid, oder Farbpigmente, wie Eisenoxidpigmente, Ruß, Kupfer, Aluminium, andere Metallpigmente, oder organische Farbpigmente auf. Der Pigmentstrich kann auch Flüssigfarbstoffe und/oder Kieselsäure und/oder Kieselsole aufweisen. Desweiteren kann der Pigmentstrich natürliche oder synthetische Bindemittel, wie Stärke, Polyvinylalkohol, Carboxymethylzellulose, Polymerdispersionen auf der Basis von Acrylsäure, Acrylester, Styrol, Butadien, Vinylacetat oder Acrylnitril enthalten. Das Verhältnis von Pigment zu Bindemittel im Pigmentstrich liegt bevorzugt zwischen 1:0,05 bis 1:1 und insbesondere 1:0,08 bis 1: 0,35, bezogen auf den Feststoffgehalt.In a preferred embodiment of the invention, the color receiving layer is in the form of a pigment coating and has organic and/or inorganic pigments and/or binders. The pigment coat preferably has white pigments, such as kaolin, calcium carbonate, aluminum hydroxide, talc, titanium dioxide, or color pigments, such as iron oxide pigments, carbon black, copper, aluminum, other metal pigments, or organic color pigments. The pigment coating can also contain liquid dyes and/or silica and/or silica sols. Furthermore, the pigment coating can contain natural or synthetic binders such as starch, polyvinyl alcohol, carboxymethyl cellulose, polymer dispersions based on acrylic acid, acrylic ester, styrene, butadiene, vinyl acetate or acrylonitrile. The ratio of pigment to binder in the pigment coat is preferably from 1:0.05 to 1:1 and in particular from 1:0.08 to 1:0.35, based on the solids content.
Bei einer bevorzugten Ausführungsform ist die Farbaufnahmeschicht aus einer Farbaufnahmemasse gebildet, die Partikel mit einem durchschnittlichen Durchmesser < 1.000 nm aufweist. Bevorzugt sind durchschnittliche Durchmesser zwischen 50 nm bis 400 nm, insbesondere zwischen 100 nm und 300 nm und bevorzugt zwischen 150 nm und 250 nm vorgesehen. Durch derart kleine Partikel werden die Fasern der Faserstruktur der Papierschicht im oberseitigen Bereich der Faserstruktur bzw. Papierschicht zumindest im wesentlichen ummantelt, wobei an der Oberseite der Papierschicht offene Zwischenräume der ummantelten Faserstruktur verbleiben. Letztlich sind oberseitig der Papierschicht eine Mehrzahl offener Zwischenräume mit einer Länge > 20 µm, vorzugsweise > 30 µm und insbesondere > 40 µm und/oder einer Öffnungsfläche > 200 µm2, vorzugsweise > 500 µm2 und insbesondere > 750 µm2 vorgesehen. Dabei sind auf der Oberseite pro Flächeneinheit [mm2] durchschnittlich wenigstens ein Zwischenraum, vorzugsweise mehr als drei und insbesondere mehr als zehn Zwischenräume vorgesehen. Bei dieser Ausführungsform können die Partikel der Farbaufnahmeschicht/-masse nicht nur aus den oben genannten Stoffen bestehen, sondern insbesondere als Hauptbestandteile Titandioxid, Bariumsulfat und Silikate aufweisen.In a preferred embodiment, the ink-receptive layer is formed from an ink-receptive composition that has particles with an average diameter of <1000 nm. Average diameters of between 50 nm and 400 nm, in particular between 100 nm and 300 nm and preferably between 150 nm and 250 nm, are preferably provided. The fibers of the fiber structure of the paper layer are at least essentially encased by such small particles in the top area of the fibrous structure or paper layer, with open interstices of the encased fiber structure remaining on the upper side of the paper layer. Ultimately, a plurality of open interstices with a length >20 μm, preferably >30 μm and in particular >40 μm and/or an opening area >200 μm 2 , preferably >500 μm 2 and in particular >750 μm 2 are provided on top of the paper layer. In this case, on average at least one gap, preferably more than three and in particular more than ten gaps are provided on the upper side per unit area [mm 2 ]. In this embodiment, the particles of the ink-receptive layer/compound can not only consist of the above-mentioned substances, but also in particular have titanium dioxide, barium sulfate and silicates as main components.
Wie eingangs bereits erwähnt worden ist, weist der obere Papierschichtbereich der Papierschicht einen geringen oder keinen Harzanteil auf. Wenngleich die Dicke des oberen Papierschichtbereichs beliebig sein kann, ist es zur Vermeidung des "Löschblatteffekts" günstig, wenn sich dieser Bereich über maximal 30% der Dicke der Papierschicht erstreckt, wobei jeder beliebige Wert zwischen 0,01% und 30% möglich und erfindungswesentlich ist. Dabei versteht es sich, daß das Material und die Porosität der Papierschicht so gewählt sind, daß eine teilweise Durchdringung der Papierschicht mit Harz und gegebenenfalls der bereits erwähnten Sperrflüssigkeit möglich ist.As mentioned above, the top paper layer portion of the paper layer has little or no resin content. Although the thickness of the upper paper layer area can be arbitrary, in order to avoid the "blotter effect" it is favorable if this area extends over a maximum of 30% of the thickness of the paper layer, with any value between 0.01% and 30% being possible and essential to the invention . It goes without saying that the material and the porosity of the paper layer are selected in such a way that partial penetration of the paper layer by resin and optionally the already mentioned barrier liquid is possible.
Insbesondere wenn die zuvor erwähnte Sperrflüssigkeit in Verbindung mit der Farbaufnahmeschicht aufgebracht wird, können sich im oberen Papierschichtbereich Feststoffe, wie Pigmente und/oder Bindemittel befinden, die dort eingelagert sind. Diese Feststoffe können dann den Materialien entsprechen, die auch in der Farbaufnahmeschicht enthalten sind.Particularly when the aforementioned barrier liquid is applied in conjunction with the ink receiving layer, there may be solids such as pigments and/or binders embedded in the top paper layer area. These solids can then correspond to the materials that are also contained in the ink-receptive layer.
Je nach Anwendungszweck sollte das Flächengewicht der Papierschicht ohne Beharzungsanteil zwischen 30 und 300 g/m2, vorzugsweise zwischen 50 und 120 g/m2 liegen. Das Flächengewicht des Beharzungsanteils sollte vorzugsweise zwischen 5 und 300 g/m2 und insbesondere zwischen 20 und 100 g/m2 liegen.Depending on the intended use, the weight per unit area of the paper layer without resin content should be between 30 and 300 g/m 2 , preferably between 50 and 120 g/m 2 . The basis weight of the resin portion should preferably be between 5 and 300 g/m 2 and in particular between 20 and 100 g/m 2 .
Bei dem Harz selbst handelt es sich um ein reaktivierbares Harz, insbesondere um ein Aminoplast, wie ein Melamin-Harz. Bevorzugt werden Harze aus der Gruppe der Diallylphtalate, Epoxidharze, Harnstoff Formaldehyd-Harze, Harnsäure-Acetylsäureester-Copolyester, Melamin-Formaldehyd-Harze, Melamin-Phenol-Formaldehyd-Harze, Phenol-Formaldehyd-Harze, Poly(meth)-acrylate oder ungesättigter Polyester-Harze verwendet.The resin itself is a reactivatable resin, in particular an aminoplast such as a melamine resin. Resins from the group of diallyl phthalates, epoxy resins, urea-formaldehyde resins, uric acid acetyl ester copolyesters, melamine-formaldehyde resins, melamine-phenol-formaldehyde resins, phenol-formaldehyde resins, poly(meth)acrylates or unsaturated resins are preferred Polyester resins used.
Die Oberseite der Farbaufnahmeschicht ist vor oder nach der Beharzung vorzugsweise durch eine sich an die Papierherstellung anschließende zusätzliche mechanische Bearbeitung, beispielsweise über Rakel oder Kalander geglättet, geschliffen und/oder fein aufgerauht, um ein etwaiges unbeabsichtigtes Verlaufen der Druckfarbe zu verhindern.The upper side of the ink receiving layer is smoothed, sanded and/or finely roughened before or after the resin application, preferably by additional mechanical processing following paper production, for example using a squeegee or calender, in order to prevent any unintentional running of the printing ink.
Es wird ausdrücklich darauf hingewiesen, daß die vorgenannten und nachstehenden Bereichsangaben und Intervalle sämtliche innerhalb der Bereichsangaben und Intervalle liegende Einzelwerte und Zwischenintervalle bzw. Zwischenbereichsangaben umfassen, ohne daß es einer ausdrücklichen Erwähnung von Einzelwerten bzw. Zwischenintervallen oder Zwischenbereichsangaben bedarf.It is expressly pointed out that the ranges and intervals mentioned above and below include all individual values and intermediate intervals or intermediate ranges within the ranges and intervals without the need for an express mention of individual values or intermediate intervals or intermediate ranges.
Nachfolgend werden Ausführungsbeispiele der Erfindung anhand der Zeichnung näher beschrieben. Dabei zeigt
- Fig. 1
- eine schematische Querschnittsansicht einer teilbeharzten Papier- schicht, die eine Farbaufnahmeschicht aufweist,
- Fig. 2
- eine qualitative Darstellung des Konzentrationsverlaufs des Harzanteils über die Schichtdicke der Papierschicht,
- Fig. 3
- eine der
Fig. 2 entsprechende Darstellung mit weiteren Konzen- trationsverläufen, - Fig. 4
- eine schematische Querschnittsansicht einer teilbeharzten Papier- schicht mit Farbaufnahmeschicht, die bereits bedruckt ist,
- Fig. 5
- eine schematische Querschnittsansicht eines flächigen Bauteils, auf dessen Grundkörper die Papierschicht aufgebracht ist,
- Fig. 6
- ein Ablaufschema des erfindungsgemäßen Verfahren und
- Fig. 7
- ein alternatives Ablaufschema eines nicht-erfindungsgemäßen Verfahrens.
- 1
- a schematic cross-sectional view of a partially resinated paper layer having an ink receiving layer,
- 2
- a qualitative representation of the concentration profile of the resin content over the layer thickness of the paper layer,
- 3
- one of the
2 Corresponding representation with further concentration curves, - 4
- a schematic cross-sectional view of a partially resinated paper layer with an ink receiving layer that has already been printed,
- figure 5
- a schematic cross-sectional view of a flat component, on the base body of which the paper layer is applied,
- 6
- a flow chart of the method according to the invention and
- 7
- an alternative flowchart of a method not according to the invention.
In
Im in
In
Letztlich sind der obere Papierschichtbereich 3 und der untere Papierschichtbereich 4 aber dadurch gekennzeichnet, daß der Konzentrationsabfall des Harzanteils im oberen Papierschichtbereich 3 wenigstens um den Faktor 2 größer ist als im unteren Papierschichtbereich 4. Dabei versteht es sich, daß der Konzentrationsabfall sehr viel größer als der Faktor 2 sein kann, wie insbesondere die Idealkurve in
Bei den dargestellten Ausführungsfbrmen ist es so, daß der obere Papierschichtbereich 3 sich über maximal 30% der Dicke d der Papierschicht 1 erstreckt. In den in
Allerdings ist darauf hinzuweisen, daß die vorliegende Erfindung nicht auf das in den
Die Farbschicht 8 ist vorliegend mittels eines nicht dargestellten Inkjet-Digitaldruckers, also mittels des Tintenstrahldruckverfahrens aufgebracht worden, wenngleich auch andere Druckverfahren, insbesondere der Tiefdruck möglich sind. Dabei werden wasserhaltige Tinten als Druckfarben eingesetzt.In the present case, the
In
Bei dem in
In
Während die zuvor beschriebene Teilbeharzung von der Unterseite 5 her grundsätzlich ausreichend ist, um einen im Vergleich zum unteren Papierschichtbereich 4 relativ schmalen oberen Papierschichtbereich 3 zu erhalten, kann es sich grundsätzlich auch anbieten, daß unmittelbar vor der Teilbeharzung auf die Druckseite 2 der Papierschicht 1 eine Sperrflüssigkeit definiert aufgebracht wird, die in die Papierschicht 1 eindringt und dabei eine Sperrschicht für das Harz bildet. Die Dicke der Sperrschicht entspricht im wesentlichen der Dicke des späteren oberen Papierschichtbereichs 3. Wichtig ist, daß die Sperrflüssigkeit sich nicht mit dem Harz mischt. Nach dem Teilbeharzen wird die Papierschicht 1 dann erwärmt, so daß die Sperrflüssigkeit verdampft. In diesem Zusammenhang kann es sich anbieten, in der Sperrflüssigkeit Feststoffe vorzusehen, die nach dem Verdampfen im oberen Papierschichtbereich 3 verbleiben.While the above-described partial resin application from the
In dem Verfahrensschritt 13 vor der Teilbeharzung, im Verfahrensschritt 14 der Teilbeharzung oder auch nach der Teilbeharzung kann die Farbaufnahmeschicht 6 mit der gewünschten Schichtdicke bzw. dem gewünschten Flächengewicht aufgebracht werden. So kann beispielsweise vorgesehen sein, daß direkt nach der Papierherstellung, also der Herstellung einer Papierbahn, die Farbaufnahmeschicht aufgebracht wird und anschließend im nächsten Verfahrensschritt beharzt wird. Die Farbaufnahmeschicht 6 kann aber auch zusammen mit der Sperrflüssigkeit auf die Oberseite 2 der Papierschicht 2 aufgebracht werden, wobei anschließend die Sperrflüssigkeit verdampft wird und die Farbaufnahmeschicht 6 verbleibt. Grundsätzlich kann auch erst nach der Teilbeharzung die Aufbringung der Farbaufnahmeschicht 6 erfolgen.In
In jedem Falle erfolgt erst nach der Teilbeharzung im Verfahrensschritt 14 und der Aufbringung der Farbaufnahmeschicht 6 im Verfahrensschritt 15 die Bedruckung und damit der Auftrag der Farbschicht 8. Die Bedruckung erfolgt im Tintenstrahldruckverfahren über Inkjet-Digitaldrucker. Beim Bedrucken kann die Papierschicht 1 noch Teil einer Papierbahn sein oder bereits Teil eines von der Papierbahn abgeschnittenen Bogens. Das Schneiden auf Bögen kann auch an späterer Stelle erfolgen.In any case, only after the partial resin application in
Parallel zum Verfahrensschritt 15 wird der Verfahrensschritt 16, nämlich die Beheizung der Druckseite und damit die Trocknung der Farbschicht 6 direkt nach dem Aufbringen auf die Farbaufnahmeschicht 6, vorgenommen. Hinzuweisen ist darauf, daß die Papierschicht 1 mit Farbaufnahmeschicht 6 grundsätzlich auch schon vor dem Bedrucken beheizt bzw. erwärmt worden sein kann, so daß die Farbe beim Bedrucken bereits auf eine vorerwärmte Papierschicht 1 trifft, was die Trocknung unterstützt. Erfindungsgemäss muss währen dem Drucken getrocknet werden.
Im Verfahrensschritt 17 wird die Papierschicht 1 mit dem Grundkörper 10 in einer entsprechenden Preßeinrichtung verpreßt. Gleichzeitig wird auch die Schutzschicht 12 verpreßt. Unter dem Druck und der Hitze der Preßplatten der Preßvorrichtung schmilzt das Harz in der Papierschicht 1 und das Harz in der Schutzschicht 12 und härtet während des Preßvorganges unmittelbar aus, so daß sich einerseits eine feste Verbindung der Papierschicht 1 zum Grundkörper 10 und andererseits eine feste Verbindung der Schutzschicht 12 auf der Papierschicht 1 ergibt. Dabei kommt es im übrigen zu einer derart festen Verbindung zwischen der Schutzschicht 12 und der Papierschicht 1, daß ein unbeabsichtigtes Ablösen der Schutzschicht 12 nicht befürchtet werden muß. ten, auf den Grundkörper 10, jedoch noch ohne Schutzschicht 12, durch Verpressen in der erwähnten Preßeinrichtung aufgebracht wird.In
In
Nach dem Verpressen der noch unbedruckten Papierschicht 1 auf dem Grundkörper 12 wird das unbedruckte Bauteil 9 nunmehr im Verfahrensschritt 21 ebenfalls im Tintenstrahldruckverfahren bedruckt. Parallel dazu oder unmittelbar anschließend erfolgt die Trocknung der aufgebrachten Farbschicht 8 im Verfahrensschritt 22. Auch hier kann natürlich eine Vorerwärmung der Papierschicht 1 bzw. der Farbaufnahmeschicht 6 vorgenommen worden sein. Hieran schließt sich die Verpressung der Schutzschicht 12 in der Preßvorrichtung im Verfahrensschritt 23 an, um die Schutzschicht 12 nach Schmelzen und Aushärten des Harzes in der Schutzschicht 12 mit der Papierschicht 1 zu verbinden.After the still
Wenngleich das in
- 11
- Papierschichtpaper layer
- 22
- Oberseitetop
- 33
- oberer Papierschichtbereichupper paper layer area
- 44
- unterer Papierschichtbereichlower paper layer area
- 55
- Unterseitebottom
- 66
- Farbaufnahmeschichtink receiving layer
- 77
- Oberseitetop
- 88th
- Farbschichtpaint layer
- 99
- Bauteilcomponent
- 1010
- Grundkörperbody
- 1111
- Oberseitetop
- 1212
- Schutzschichtprotective layer
- 1313
- Papierherstellungpapermaking
- 1414
- Teilbeharzungpartial resination
- 1515
- BedruckungOppression
- 1616
- Trocknungdrying
- 1717
- Verpressungcompression
- 1818
- Papierherstellungpapermaking
- 1919
- Teilbeharzungpartial resination
- 2020
- Verpressungcompression
- 2121
- BedruckungOppression
- 2222
- Trocknungdrying
- 2323
- Verpressungcompression
Claims (11)
- Method for producing a planar, printed component (9), in particular for floor, wall, ceiling and/or furniture applications, a resin-treated paper layer (1) which is printed with an ink layer (8) being applied under the influence of pressure and heat to a planar base body (10) of the component (9),
characterized
in that the ink layer (8) applied is dried during the printing by means of at least one heating device, in that the heating temperature is between 30°C and 150°C, resulting in immediate drying of applied ink, the ink being water-containing and the heating device being an infrared, particularly NIR, and/or microwave heating device, and in that the paper layer (1) is pressed, in a short-cycle pressing method, with the base body (10) and a protective layer (12) which is also resin-treated and applied to the ink layer (8), the temperature during the pressing being between 140°C and 200°C. - Method according to Claim 1, characterized in that the paper layer (1) is not completely resinated throughout, the surface of the paper layer (1) being at least partly, preferably at least substantially, resin-free, and a separate ink acceptance layer (6) which rests on the paper layer (1) and is intended for application of the ink layer (8) being applied to the top (2) of the paper layer (1).
- Method according to Claim 1 or 2, characterized in that the ink layer (8) is applied directly to the ink acceptance layer (6) and/or in that the ink acceptance layer (6) is applied to the entire top (2) of the paper layer (1) over the whole area and/or in that the ink acceptance layer (6) completely covers the top (2) of the paper layer (1).
- Method according to any of the preceding claims, characterized in that the paper layer (1) is resin-treated in a defined manner from the bottom (5) in such a way that the upper paper layer region (3) facing the printed side (2) and comprising little or no resin extends over not more than 30% of the thickness (d) of the paper layer (1).
- Method according to any of the preceding claims, characterized in that the amount of resin fed to the bottom (5) is controlled in a defined manner by means of the process as a function of the viscosity of the resin and absorptivity of the paper layer (1).
- Method according to any of the preceding claims, characterized in that the paper layer (1), prior to the resin treatment, is impregnated from the top (2) with a barrier liquid which does not mix with the resin and/or with a liquid comprising particles of the ink acceptance layer.
- Method according to any of the preceding claims, characterized in that the paper layer (1) is impregnated from the top (2) in a defined manner with the barrier liquid and/or the liquid comprising particles of the ink acceptance layer, in such a way that a barrier layer for the resin, which extends over at most 30% of the thickness (d) of the paper layer (1), forms.
- Method according to any of the preceding claims, characterized in that the barrier liquid and/or the liquid comprising particles of the ink acceptance layer is evaporated after the resin treatment of the paper layer (1).
- Method according to any of the preceding claims, characterized in that the resin treatment is effected before, during or after application of the ink acceptance layer (6).
- Method according to any of the preceding claims, characterized in that the paper layer (1) is printed on before or after the application to the base body (10).
- Method according to any of the preceding claims, characterized in that the paper layer (1) is printed only after the application of the ink acceptance layer (6) and after the resin treatment.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PL08716179.0T PL2132043T5 (en) | 2007-03-15 | 2008-03-03 | Method for producing a flat, printed component |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102007013133A DE102007013133A1 (en) | 2007-03-15 | 2007-03-15 | Method for producing a flat, printed component |
PCT/EP2008/001658 WO2008110276A1 (en) | 2007-03-15 | 2008-03-03 | Method for producing a flat, printed component |
Publications (3)
Publication Number | Publication Date |
---|---|
EP2132043A1 EP2132043A1 (en) | 2009-12-16 |
EP2132043B1 EP2132043B1 (en) | 2011-01-12 |
EP2132043B2 true EP2132043B2 (en) | 2023-08-09 |
Family
ID=39471835
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP08716179.0A Active EP2132043B2 (en) | 2007-03-15 | 2008-03-03 | Method for producing a flat, printed component |
Country Status (7)
Country | Link |
---|---|
EP (1) | EP2132043B2 (en) |
AT (1) | ATE495021T1 (en) |
DE (2) | DE102007013133A1 (en) |
DK (1) | DK2132043T4 (en) |
ES (1) | ES2358961T5 (en) |
PL (1) | PL2132043T5 (en) |
WO (1) | WO2008110276A1 (en) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2743094B1 (en) * | 2012-12-12 | 2015-06-03 | Flooring Technologies Ltd. | Method for the manufacture of a board provided with a decorative layer |
DE102017215373A1 (en) * | 2017-09-01 | 2019-03-07 | Koenig & Bauer Ag | Mixture for a pre-coating of decorative papers and method for the production of printed decorative paper in a printing press |
CN112252082B (en) * | 2020-10-14 | 2022-11-22 | 山东凯丽特种纸股份有限公司 | Watercolor paper with printing function and preparation method thereof |
EP4086081A1 (en) | 2021-05-07 | 2022-11-09 | Swiss Krono TEC AG | Digital printing method |
Citations (2)
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DE69304774T2 (en) † | 1992-05-01 | 1997-02-20 | Hewlett Packard Co | Heater blower assembly in a color jet printer |
EP1580010A2 (en) † | 2004-03-23 | 2005-09-28 | Fuji Photo Film Co., Ltd. | Ink jet image forming apparatus and method |
Family Cites Families (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3528735A1 (en) | 1985-08-10 | 1987-02-12 | Sueddeutsche Kalkstickstoff | QUICK-HARDING CONDENSATION PRODUCT AND METHOD FOR PRODUCING IT |
DE19715268A1 (en) * | 1997-04-12 | 1998-10-15 | Kaemmerer Gmbh | Laminating sheet, e.g. for chipboard laminates |
DE19916546C2 (en) * | 1999-04-13 | 2001-05-03 | Technocell Dekor Gmbh & Co Kg | Inkjet recording layer |
DE19955081C1 (en) * | 1999-11-15 | 2001-08-09 | Schoeller Felix Jun Foto | Base paper for a recording material for the ink jet printing process |
US7169460B1 (en) * | 1999-12-14 | 2007-01-30 | Mannington Mills, Inc. | Thermoplastic planks and methods for making the same |
DE10134302C1 (en) * | 2001-07-14 | 2002-12-12 | Technocell Dekor Gmbh & Co Kg | Pre-impregnate obtained by impregnation of crude paper with a thermally hardenable formaldehyde-free resin useful in the production of decorative impregnates or coatings, and surface treatment of printed and unprinted papers |
EP1664432B1 (en) | 2003-09-16 | 2017-08-02 | Voith Patent GmbH | Method and device for producing decorative paper and the use thereof |
US7799735B2 (en) * | 2005-06-01 | 2010-09-21 | Ronald Segall | Chemically modified melamine resin for use in sublimation dye imaging |
DE102005036541B9 (en) | 2005-08-03 | 2010-02-11 | Bauer, Jörg R. | Process for producing a paper surface, paper web and article coated therewith in particular by means of an inkjet printing process |
-
2007
- 2007-03-15 DE DE102007013133A patent/DE102007013133A1/en active Pending
-
2008
- 2008-03-03 ES ES08716179T patent/ES2358961T5/en active Active
- 2008-03-03 DK DK08716179.0T patent/DK2132043T4/en active
- 2008-03-03 EP EP08716179.0A patent/EP2132043B2/en active Active
- 2008-03-03 DE DE502008002290T patent/DE502008002290D1/en active Active
- 2008-03-03 PL PL08716179.0T patent/PL2132043T5/en unknown
- 2008-03-03 WO PCT/EP2008/001658 patent/WO2008110276A1/en active Application Filing
- 2008-03-03 AT AT08716179T patent/ATE495021T1/en active
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
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DE69304774T2 (en) † | 1992-05-01 | 1997-02-20 | Hewlett Packard Co | Heater blower assembly in a color jet printer |
EP1580010A2 (en) † | 2004-03-23 | 2005-09-28 | Fuji Photo Film Co., Ltd. | Ink jet image forming apparatus and method |
Non-Patent Citations (2)
Title |
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"Taschenbuch der Spanplattentechnik", 2000, article DEPPE HANS-JOACHIM, KURT ERNST: "Taschenbuch der Spanplattentechnik", pages: 320 - 335 † |
DE-Z Das Papier 3/2006, S. 38-45 † |
Also Published As
Publication number | Publication date |
---|---|
DK2132043T4 (en) | 2023-11-13 |
ES2358961T5 (en) | 2024-03-26 |
DE502008002290D1 (en) | 2011-02-24 |
DE102007013133A1 (en) | 2008-09-18 |
PL2132043T3 (en) | 2011-07-29 |
PL2132043T5 (en) | 2023-12-18 |
EP2132043A1 (en) | 2009-12-16 |
ES2358961T3 (en) | 2011-05-17 |
EP2132043B1 (en) | 2011-01-12 |
DK2132043T3 (en) | 2011-05-02 |
WO2008110276A1 (en) | 2008-09-18 |
ATE495021T1 (en) | 2011-01-15 |
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